Poly(3-hydroxybutyrate) Resin Sheet Thermoforming Uniformity
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Solution Overview
Problem
Poly(3-hydroxybutyrate) resin sheets used for thermoforming often result in molded bodies with locally thinned regions, leading to strength and shape defects, especially when forming deep cavities.
Innovation Solution
A poly(3-hydroxybutyrate) resin sheet with specific crystalline melting behavior, characterized by a melting point peak temperature difference of 10° C. or more, and a thickness of 0.15 to 1 mm, which allows for uniform preheating and stretching during thermoforming, resulting in molded bodies with a relatively uniform thickness and good appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a poly(3-hydroxybutyrate) resin sheet is subjected to thermoforming to create deep cavity molded bodies, then the molded body can be formed with complex shapes, but the sheet develops locally thinned regions resulting in strength defects and shape defects
Solution Approach 1:
The patent applies parameter changes by controlling the melting point characteristics of the poly(3-hydroxybutyrate) resin. Specifically, the resin is designed to have a melting point peak temperature difference of 10°C or more between DSC heating rates of 5°C/min and 10°C/min. This parameter control allows the resin to maintain appropriate viscosity during thermoforming, preventing local thinning while enabling deep cavity forming, thus resolving the contradiction between adaptability and strength.
2Productivity
If a poly(3-hydroxybutyrate) resin sheet is subjected to thermoforming, then molded bodies can be produced, but the molded bodies exhibit rough surfaces and appearance defects
Solution Approach 1:
The patent controls the melting point peak temperature difference as a key parameter to prevent rough surface formation. By ensuring the DSC heating rate difference (5°C/min vs 10°C/min) produces a melting point peak temperature difference of 10°C or more, the resin maintains stable flow characteristics during thermoforming, eliminating appearance defects while preserving production efficiency.
3Ease of manufacture
If conventional poly(3-hydroxybutyrate) resin sheets are used for thermoforming, then processing can be performed, but the sheets fail to provide sufficient strength and exhibit shape defects
Solution Approach 1:
The patent modifies the resin's thermal parameters by controlling its melting point behavior. The specific requirement that the melting point peak temperature difference between DSC heating rates of 5°C/min and 10°C/min be 10°C or more ensures the resin has optimal viscosity characteristics for thermoforming. This parameter optimization maintains ease of manufacture while significantly improving structural integrity and eliminating shape defects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The described poly(3-hydroxybutyrate) resin sheet is quickly degradable in seawater and can be thermoformed into molded bodies with high strength and good appearance, effectively addressing the issues of local thinning and shape defects.
Implementation Method 1
a sheet made of a poly(3-hydroxybutyrate) resin exhibiting a particular crystalline melting behavior
Implementation Method 2
poly(3-hydroxybutyrate) resins, which can be readily biodegraded even in seawater
Data Source
AI summary
Provided is a resin sheet for thermoforming, the resin sheet containing a poly(3-hydroxybutyrate) resin. A difference between a melting point peak temperature and a melting point peak end temperature in differential scanning calorimetry analysis of the poly(3-hydroxybutyrate) resin is 10° C. or more. The sheet has a thickness of 0.15 to 1 mm. The melt viscosity of the poly(3-hydroxybutyrate) resin at 160° C. is preferably 10000 poise or more.